Self-Funded PhD Students Only
About the Project
The rapid growth of the global space sector is creating increasing demand for lightweight, high-performance, and cost-effective satellite structures. Small satellites, particularly CubeSats, have transformed access to space by providing affordable platforms for Earth observation, communications, navigation, climate monitoring, scientific research, and defence applications. However, CubeSat structural frames are still predominantly manufactured from aluminium alloys, which add mass, impose design…
constraints, and contribute significantly to manufacturing and launch costs.
This PhD project aims to develop next-generation CubeSat structural systems using advanced polymers, polymer composites, and additive manufacturing technologies.
Building on recent advances in high-performance engineering polymers and fibre-reinforced composites, the research will investigate how 3D printing can be used to replace conventional metallic satellite structures while maintaining the strength, stiffness, durability, and dimensional stability required for space applications.
One of the most important challenges in satellite engineering is reducing overall system mass. Every kilogram launched into orbit carries a significant financial penalty.
Lightweight CubeSat structures can reduce launch costs while enabling larger payloads such as sensors, communication systems, scientific instruments, batteries, and propulsion units. Weight savings achieved through advanced polymer composite structures can therefore improve mission capability without increasing launch costs.
Additive manufacturing offers unique opportunities for the aerospace sector by enabling highly optimised geometries, lattice structures, topology-optimised designs, and reduced material waste. Unlike conventional machining and fabrication methods, 3D printing enables rapid development cycles, lower tooling costs, greater design freedom, and more sustainable manufacturing approaches. Advanced polymer composites also offer excellent strength-to-weight ratios, corrosion resistance, vibration damping characteristics, and the potential for significant structural mass reduction.
The PhD will focus on the design, optimisation, manufacture, and testing of lightweight CubeSat frames using advanced polymers and composite materials. The successful candidate will investigate material selection, structural performance, manufacturing feasibility, thermal and environmental durability, and the impact of structural mass reduction on launch costs and mission performance. The project will also explore how additive manufacturing can enable innovative satellite architectures that are difficult or impossible to manufacture using conventional metallic fabrication techniques.
Host institution
The project will be hosted at Loughborough University, one of the UK's leading research intensive universities, with an international reputation for excellence in aerospace engineering, advanced materials, digital manufacturing, and high-value engineering research.
The research will be based within the Wolfson School of Mechanical, Electrical and Manufacturing Engineering, home to world-leading research in additive manufacturing, advanced composites, lightweight structures, digital design, and aerospace technologies.
The School has a long-standing track record of delivering impactful research and industrial innovation through close collaborations with aerospace, automotive, energy, and manufacturing sectors.
The project will benefit from access to Loughborough's state-of-the-art additive manufacturing and materials characterisation facilities, providing capabilities for the design, manufacture, and testing of advanced polymer and composite structures. These facilities support research across the complete product development cycle, from computational design and topology optimisation through to prototype manufacture, structural evaluation, and performance validation.
The successful candidate will join a vibrant multidisciplinary research environment bringing together expertise in additive manufacturing, polymer engineering, composite materials, structural mechanics, aerospace systems, and sustainable manufacturing.
The project aligns closely with the University's strategic research strengths in advanced manufacturing and future mobility and offers opportunities for collaboration with leading industrial partners and researchers working on next-generation space technologies.
This unique research environment will provide an excellent platform for developing innovative 3D-printed CubeSat structures and advancing the use of advanced polymer composites for future satellite applications.
The PhD student will gain expertise in:
- Advanced polymers and composite materials
- CubeSat design and space structures
- Additive manufacturing and 3D printing technologies
- Space Structures Design and Manufacturing
- Materials characterisation and performance evaluation
- Experimental structural testing
- Sustainable and digital manufacturing
Research environment and collaboration
The project sits at the interface of space technology, advanced materials, and additive manufacturing. The student will have access to state-of-the-art facilities for materials development, structural testing, digital manufacturing, and computational modelling.
Opportunities for collaboration with academic researchers and industrial partners working in aerospace, advanced manufacturing, and space technologies will provide a highly stimulating research environment.
Potential impact
The successful development of lightweight 3D-printed polymer composite CubeSat structures could contribute to a new generation of affordable and high-performance satellite systems through:
- Reduced launch costs through significant structural mass reduction
- Increased payload capacity for scientific instruments and communication systems
- Improved mission performance and operational lifetime
- Faster and lower-cost manufacturing compared with conventional metallic fabrication
- Enhanced design freedom through topology optimisation and lattice structures
- Reduced material waste and improved manufacturing sustainability
- Accelerated development of future space technologies and small satellite platforms
The outcomes of the project could support advances in Earth observation, communications, environmental monitoring, scientific exploration, defence technologies, and commercial space applications.
94% of Loughborough’s research impact is rated world-leading or internationally excellent. REF 2021
Supervisors
- Primary supervisor: Dr Sameer Rahatekar
- Secondary supervisor: Professor Richard Blanchard
Entry requirements
Applicants should have, or expect to achieve, at least a 2:1 honours degree (or equivalent) in Engineering, Materials Science, Polymers, composites, textiles or physical sciences (chemistry, physics and related discipline).
English language requirements
Applicants must meet the minimum English language requirements. Further details are available on the International website.
Tuition fees for 2026-27 entry
- UK fee - £5,238 Full-time degree per annum
- International fee - £29,500 Full-time degree per annum
How to apply
All applications should be made online.
Under Campus, please select Loughborough and select Programme Mechanical and Manufacturing Engineering.
Please quote the advertised reference number ‘SF-SR-2026-3’ under the finance section in your application.
Applications must include:
- A personal statement
- An up-to-date curriculum vitae (CV)
- Details of two referees (one from your highest degree qualification)
- Certified certificates and transcripts for all completed degree programmes
- A clear reference to the project SF-SR-2026-3
To avoid delays in processing your application, please ensure that you submit all required supporting documents with your application.
